Clutch Pedal Adjustment

Drivetrain. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
Clutch. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY

Clutch Pedal -- Adjustment



1. INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY

  1. Fold back the floor carpet to expose the asphalt sheet under the pedal.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Clutch.Clutch System.Clutch Pedal Adjustment

  1. Check that the pedal height is correct.

    Text in Illustration
    *a
    		Pedal Height
    *b
    		Pedal Height Adjustment Point
    *c
    		Push Rod Play
    *d
    		Push Rod Play Adjustment Point
    Pedal height from dash panel:
    179.6 to 189.6 mm (7.07 to 7.46 in.)

  1. w/o Clutch Switch:
    Adjust the pedal height.

    1. Loosen the lock nut of the stopper bolt and turn the stopper bolt until the pedal height is within the specified range.

    2. Tighten the lock nut.

      Torque:
      25 N*m{255 kgf*cm, 18 ft.*lbf}

  1. w/ Clutch Switch:
    Adjust the pedal height.

    1. Loosen the lock nut of the stopper bolt and the clutch switch. Then turn the clutch switch backward.

    2. Turn the stopper bolt until the pedal height is within the specified range.

    3. Tighten the lock nut of the stopper bolt.

      Torque:
      25 N*m{255 kgf*cm, 18 ft.*lbf}

    4. Adjust the clutch switch assembly (HILUX_TGN26 RM000004FUB00UX.html).



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Clutch.Clutch System.Clutch Pedal Adjustment

  1. Check the pedal free play and push rod play.

    Text in Illustration
    *a
    		Push Rod Play
    *b
    		Pedal Free Play

    1. Depress the clutch pedal until resistance is felt.

    2. Measure the distance between the position of the pedal when it is released and the position in the previous step.

      Standard pedal free play:
      5.0 to 15.0 mm (0.197 to 0.591 in.)

    3. Release the pedal. Using your finger, gently press the pedal until resistance increases slightly.

    4. Measure the distance between the position of the pedal when it is released and the position in the previous step.

      Standard push rod play at pedal top:
      1.0 to 5.0 mm (0.0394 to 0.197 in.)

  1. Adjust the pedal free play and push rod play.

    1. Loosen the lock nut and turn the push rod until the pedal free play and push rod play are within the specified range.

    2. Tighten the lock nut.

      Torque:
      12 N*m{120 kgf*cm, 9 ft.*lbf}

    3. After adjusting the pedal free play, check the pedal height.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Clutch.Clutch System.Clutch Pedal Adjustment

  1. Check the clutch release point.

    Text in Illustration
    *a
    		25 mm or more
    *b
    		Release Point
    *c
    		Pedal Stroke
    *d
    		Full Stroke End Position

    1. Pull the parking brake lever and use wheel chocks to stabilize the vehicle.

    2. Start the engine and run it at idle.

    3. Without depressing the clutch pedal, slowly move the shift lever to R until the gears contact each other.

    4. Gently depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

      Standard distance A:
      25 mm (0.984 in.) or more
      If the distance is not as specified, perform the following operations.
      1. Check pedal height.
      2. Check push rod play and pedal free play.
      3. Bleed air from clutch line.
      4. Check clutch cover and disc.